Blast Optimisation, Multi-component models, Energy Efficient Circuits and Integrated Extraction Software

Program two integrates data from across multi-stream and multi-grade circuits to simulate their performance and assist in the selection of the most efficient circuit design. The program’s objective is to leverage every material handling transition as an opportunity to separate waste and upgrade metal content. While evaluation of individual circuit components has been possible for some time, CRC ORE’s mine extraction simulation software will link all elements of the process with techniques for measuring energy and water use to assess downstream impact.

Selective Blast Design

Blastech integrated blasting software for open pit mines draws on three years of prior research to develop a single software interface to import geological information and optimise blast design and charging. Blasting considerations can be made for fragmentation, movement (grade control) and metal concentration. The software enables selective blasting techniques to be employed in a mass mining environment.

Dynamic blast design leverages the geotechnical block models developed by Program 1 to produce pattern design parameters for concentrating blast energy. With rock breakage accounting for 60% of mine site energy consumption, reducing the size of feed to the mill can have a significant economic effect. Selective Liberation utilises chemical energy (the most cost effective form of energy) to increase fragmentation in regions of high metal concentration, resulting in substantial energy savings across the circuit.

Selective blast design is assisted by Blast Movement Monitor (BMM) technology, using marker beacons within the drill holes to track the three dimensional displacement of the rock mass.

SEE – Integrated Extraction Simulators

SEE is a software based, fully integrated extraction simulator that considers key eco-efficiency attributes and enables long term improvement. The program draws on a database of mineral properties and performance attributes to calculate mining block, mining process and minerals process models to optimise mineral extraction. The simulation outputs information including cost per tonne, energy consumption, water use and carbon emissions, enabling mine managers to make rapid decisions about the viability of multiple extraction methods. The system also integrates corporate knowledge capture functions and workflow reporting, providing functionality at both strategic and operational levels.

CRC ORE is developing a generic system of SEE to expand on the prototype developed by the University of Queensland’s Bryan Research Centre and make the software package applicable to all mining operations. This will also provide the integration platform for CRC ORE’s characterisation, blasting and novel circuit design programs, and deliver inputs for Program 3’s evaluation research.

Energy Efficient Circuits

Energy efficient circuits are the route to significant energy and cost reductions by rejecting gangue and upgrading ore early in the extraction process. Staged reduction processes access the product at various stages of the comminution process, separating the ore according to grade and enabling grinding and processing prioritisation according to value. This enables more efficient equipment use by assigning the correct equipment to the process

Flexible circuits are designed to meet current and future demands by allowing for the uptake of new technology. These circuits are able to respond to ore body variability and are intrinsically controllable with zero energy expansion. Robust base performance provides a low risk foundation for the circuits, with potential benefits for high performance recovery, energy use and cleaner waste. The energy efficient circuits program will produce novel, proven circuit designs that are assessable using tools such as SEE.

Telfer Resource Upgrade Project

CRC ORE has partnered with Newcrest Mining to validate new technologies at the Telfer gold and copper mine in Western Australia. Telfer will see innovative circuit designs coupled with analytical software packages to increase ore grade while significantly decreases energy and water consumption. Read more about the Telfer Integrated Case Study here...